Equipment Design - 4th year Assist. Prof. Ihsan Habib Dakhil References 1. Sinnott RK and Towler C., "Chemical Engineering Design," Sth edition Butterworth-Heinemann, (2009). 2. Coke A.K., "Ludwig Applied Process Design of Chemical and Petrochemical Plant." vol. 1, 4th edition Gulf professional Publisher, (2007). 3, Branan C., "Rules of Thumbs for Chemical Engineers,"4th edition Gulf professional Publisher, (2005). 4. Couper J., Penny W.R, Fair J. and Walas, "Chemical Process Equipment," 2nd edition, (2010). 5. Peters M, Timmerhause K.D and West R, "Plant Design and Economics for Chemical Engineers," Sth edition McGraw-Hill, (2003). 6. Perry R and Green D; “Perry's Chemical Engineers Handbook," 7th edition McGraw —Hill, (1997). 7. Sinnott R.K., "Chemical Engineering Design," vol. 6, 4" edition, Coulson & Richardson's Chemical Engineering Series, Elsevier Butterworth-Heinemann, (2005). Courses Requirements: - Equipment design has two courses each course includes 45 hours per course. All students have to attend course lectures, doing daily and monthly exams, otherwise, unexcused absent for 10% (5 hours) of the total course hours will cause failure in this course. The optional activities for equipment design are participating to solve industrial problems and challenge design day. Feel free to contact me at office hours or in emergency cases at the following emails: em2ihsan@mu.edu.iq; em2ihsan@yahoo.comEquipment Design - 4th year Chapter One Assist. Prof. Ihsan Habib Dakhil Chapter One Basic Concepts 1.1 Introduction Design is a creative activity, and as such can be one of the most rewarding and satisfying activities undertaken by an engineer. The designer begins with a specific objective or customer need in mind and, by developing and evaluating possible designs, arrives at the best way of achieving that objective for the chemical engineer, a new chemical product or production process. When considering possible ways of achieving the objective, the designer will be constrained by many factors, which will narrow down the number of possible designs. There will rarely be just one possible solution to the problem, just one design. Several alternative ways of meeting the objective will normally be possible, even several best designs, depending on the nature of the constraints. 1- Economic considerations are obviously a major constraint on any engineering design: plants must make a profit. 2- Time will also be a constraint. The time available for completion of a design will usually limit the number of alternative designs that can be 3+ Physical laws. 4- Resources. 5- Safety Regulations. 6- Standard and codes. These set the outer boundary of possible designs, as shown in figure below. Within this boundary, there will be a number of plausible designs bounded by the other. Economic considerations are obviously a major constraint on any engineering design. Time will also be a constraint. The time available for completion of a design will usually limit the number of alternative designs that can be considered. ee ae eed: Lal SES AeA aN) Cn ona f adigh 267 gh daleEquipment Design - 4th year Chapter One Assist. Prof. Ihsan Habib Dakhil Plausible designs —— “External” constraints Internal” constraints ‘The stages in the development of a design, from the initial identification of the objective to the final design, are shown diagrammatically in figure below. This figure shows design as an iterative procedure; as the design develops, the designer will be aware of more possibilities and more constraints, and will be constantly seeking new data and ideas, and evaluating possible design solutions. Objective (design specication) —t \ \ | [ouecten of cata A physical 1 1 ' properties design ‘methods a r { Generation of Selection and ‘evaluation (optimisation) eee Final desion fr possible cess JHB cae ght: Solalh 3a 3 AeA aN) Cn ona f adigh 267 gh daleEquipment Design - 4th year Chapter One Assist. Prof. Ihsan Habib Dakhil 1.2 Generation of Possible Design Concepts Chemical engineering projects can be divided into three types, depending on the novelty involved: 1. Modifications, and additions, to existing plant; usually carried out by the plant design group. 2. New production capacity to meet growing sales demand, and the sale of established processes by contractors. Repetition of existing designs with only minor design changes. 3, New processes, developed from laboratory research, through pilot plant, to a commercial process. Even here, most of the unit operations and process equipment will use established designs. 1.3 Data Collection Process design will include information on possible processes, equipment performance, and physical property data. This stage can be one of the most time consuming. Most organizations will have design manuals covering preferred methods and data for the more frequently used, routine, design procedures. Setting the Design Basis The most important step in starting a process design is translating the customer need into a design basis. It will normally include the production rate of the main product together with the information on constraints that will influence the design such as: 1- The system of the units to be used. 2- The national, local or company design codes that must be followed. 3- Details of raw materials that available. 4- Information on potential sites where the plant might be located. 5- Information on the condition, availability and prices of utility services. ee ae eed: Lal SES : AeA aN) Cn ona f adigh 267 gh daleEquipment Design - 4th year Chapter One Assist. Prof. Ihsan Habib Dakhil 1.4 The Anatomy of A chemical Manufacturing Process Chemical engineering design is concerned with the selection and arrangement of the stages and the selection, specification, and design of the equipment required to perform the function of each stage. Recycie of unreacted By-products _». wis Ay ‘ Raw] Y — maternal —'>} | Feed | » {Reaction > Product Product | » | Product! [sales] eotias reparation | separation purification Storage | Stage 1. Raw material storage Unless the raw materials (also called essential materials, or feed stocks) are supplied as intermediate products (intermediates) from a neighboring plant, some provision will have to be made to hold several days, or weeks, storage to smooth out fluctuations and interruptions in supply. Stage 2. Feed preparation Some purification, and preparation, of the raw materials will usually be necessary before they are sufficiently pure, or in the right form, to be fed to the reaction stage. Stage 3. Reactor The reaction stage is the heart of a chemical manufacturing process. In the reactor the raw materials are brought together under conditions that promote the production of the desired product; invariably, by-products and unwanted compounds (impurities) will also be formed. Stage 4. Product separation In this first stage after the reactor, the products and by-products are separated from any unreacted material. If in sufficient quantity, the unreacted material will be recycled to the reactor. They may be returned directly to the reactor, or to the feed purification and preparation stage. The by-products may also be separated from the products at this stage. ee ae eed: Lal SES AeA aN) Cn ona f adigh 267 gh daleEquipment Design - 4th year Chapter One Assist. Prof. Ihsan Habib Dakhil Stage 5. Purification Before sale, the main product will usually need purification to meet the product specification. If produced in economic quantities, the by-products may also be purified for sale. Stage 6. Product storage Some inventory of finished product must be held to match production with sales. Provision for product packaging and transport will also be needed, depending on the nature of the product. Liquids will normally be dispatched in drams and in bulk tankers (road, rail and sea), solids in sacks, cartons or bales. The stock held will depend on the nature of the product and the market. Ancillary Processes In addition to the main process stages, provision will have to be made for the supply of the services (utilities) needed; such as, process water, cooling water, compressed air, steam. Facilities will also be needed for maintenance, firefighting, offices and other accommodation, and Laboratories. 1.5 Continuous and Batch Processes: Continuous processes are designed to operate 24 hours a day, 7 days a week, throughout the year. Some down time will be allowed for maintenance and, for some processes, catalyst regeneration. The plant attainment; that is, the percentage of the available hours in a year that the plant operates, will usually be 90 to 95%. hours operated ,Continuous processes will usually be more economical for large scale production. Batch processes are designed to operate intermittently. Some, or all, the process units being frequently shut down and started up. Batch processes are used where some flexibility is wanted in production rate or product specification. ee ae eed: Lal SES : AeA aN) Cn ona f adigh 267 gh dale